US20090087083A1 - Infra-red thermal imaging of laser welded battery module enclosure components - Google Patents
Infra-red thermal imaging of laser welded battery module enclosure components Download PDFInfo
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- US20090087083A1 US20090087083A1 US12/330,787 US33078708A US2009087083A1 US 20090087083 A1 US20090087083 A1 US 20090087083A1 US 33078708 A US33078708 A US 33078708A US 2009087083 A1 US2009087083 A1 US 2009087083A1
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- weld
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- battery module
- enclosure components
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- 238000012545 processing Methods 0.000 claims abstract description 13
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- 238000000034 method Methods 0.000 claims description 17
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- 239000004416 thermosoftening plastic Substances 0.000 claims description 7
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- 238000003466 welding Methods 0.000 description 16
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 3
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- 238000004023 plastic welding Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/44—Resins; rubber; leather
- G01N33/442—Resins, plastics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
- B29C65/7879—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined said parts to be joined moving in a closed path, e.g. a rectangular path
- B29C65/7882—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined said parts to be joined moving in a closed path, e.g. a rectangular path said parts to be joined moving in a circular path
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/82—Testing the joint
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
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- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
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- B29C66/01—General aspects dealing with the joint area or with the area to be joined
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- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/114—Single butt joints
- B29C66/1142—Single butt to butt joints
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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- B29C66/53—Joining single elements to tubular articles, hollow articles or bars
- B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
- B29C66/5344—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends
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- B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
- B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
- B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N25/00—Investigating or analyzing materials by the use of thermal means
- G01N25/72—Investigating presence of flaws
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
- B29C66/952—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the wavelength
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/712—Containers; Packaging elements or accessories, Packages
- B29L2031/7146—Battery-cases
Abstract
A thermal imaging system for a battery module enclosure that includes first and second battery module enclosure components between which a weld is formed includes a thermal imaging camera that focuses on the first and second battery module enclosure components within a predetermined amount of time after the weld is formed and that acquires a thermal signature. A control module includes an image processing module that receives the thermal signature and that locates a predetermined reference point in the thermal signature. An image comparison module receives the thermal signature and uses the predetermined reference point to compare the thermal signature to a template signature in order to verify structural integrity of the weld. The image comparison module computes a relative measure of deviation of the thermal signature from the template signature and identifies the weld as defective when the relative measure of deviation is greater than a predetermined value.
Description
- This application is a Divisional Application of U.S. patent application Ser. No. 11/211,021, filed Aug. 24, 2005. The entire disclosure of the above application is incorporated herein by reference.
- The present invention relates to thermal imaging of plastic welds, and more particularly to infra-red thermal imaging of thermoplastic components used in battery module enclosures.
- Battery module enclosures house one or more battery cells that are utilized to provide electrical power. For example, a battery module enclosure may include multiple battery cells connected in series to provide a desired voltage. In some cases, the battery cells comprise liquid materials such as potassium hydroxide and require airtight sealing from an exterior of the battery module as well as between individual cells to prevent a short-circuit condition. Additionally, the battery modules are often utilized in physically unstable environments such as vehicles for hybrid electric applications. Therefore, battery module enclosures commonly comprise thermoplastic materials such as polymeric blends. Since the battery module enclosures typically include at least two interfacing components, welding is often required to create a seal between the multiple components.
- Ideally, such welding results in electrically isolated cell pockets. However, variation among plastic components used to make the battery module enclosures creates the possibility of weak or even non-existent welds at defective regions. For example, variations may occur during a molding process or during shipping or handling of plastic components. In one approach, quality control and inspection techniques are used to detect external leakage and/or identify weak welds. However, external inspection of battery module enclosures cannot identify internal leakage or weak welds that are not visibly apparent. Additionally, it is costly and time consuming to manually inspect every weld of every plastic enclosure component that is manufactured.
- A thermal imaging system for a battery module enclosure that includes first and second battery module enclosure components between which a weld is formed according to the present invention includes a thermal imaging camera that focuses on the first and second battery module enclosure components within a predetermined amount of time after the weld is formed and that acquires a thermal signature. A control module includes an image processing module that receives the thermal signature and that locates a predetermined reference point in the thermal signature. An image comparison module receives the thermal signature and uses the predetermined reference point to compare the thermal signature to a template signature in order to verify structural integrity of the weld.
- In other features, the thermal imaging camera is an infra-red thermal imaging camera. The image processing module utilizes an image processing algorithm that locates a structural feature that is common to both of the thermal and template signatures. The first and second battery module enclosure components comprise polymeric thermoplastics. The battery module enclosure houses at least one battery cell for a hybrid electric vehicle. A laser source focuses a laser beam on the first and second module enclosure components in order to form the weld. The first and second module enclosure components are fixed on a turntable that includes a motor. The control module includes a turntable module that adjusts a position of the turntable so that the first and second module enclosure components are located within a path of the laser beam when the laser source forms the weld and so that the first and second module enclosure components are within a field of view of the thermal imaging camera when the thermal imaging camera acquires the thermal signature.
- In still other features of the invention, the image comparison module computes a relative measure of deviation of the thermal signature from the template signature and identifies the weld as defective when the relative measure of deviation is greater than a predetermined value. A data module stores the template signature. The image comparison module stores the thermal signature and a weld integrity value that is associated with the thermal signature in the data module after the image comparison module verifies structural integrity of the weld. A data analysis module generates weld integrity statistics based on a plurality of weld integrity values that are stored in the data module.
- Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
- The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
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FIG. 1 is a functional block diagram of a thermal imaging system for plastic enclosure components of a battery module according to the present invention; -
FIG. 2A is a front view of an exemplary single-cell battery module enclosure; -
FIG. 2B is a side cross-section of the single-cell battery module enclosure illustrating interfaces between plastic battery module enclosure components; -
FIG. 2C is a scaled partial view ofFIG. 2B illustrating a weld made between the plastic enclosure components using laser welding; -
FIG. 3A is a first cross-section of the single-cell battery module enclosure illustrating welding along an interface between two plastic enclosure components; -
FIG. 3B is a thermal signature of the single-cell battery module enclosure ofFIG. 3A from a top view perspective following a welding procedure; -
FIG. 4 illustrates an exemplary thermal signature gradient that identifies visual image fluctuations in thermal signatures due to temperature variations; -
FIG. 5A is a second cross-section of the single-cell battery module enclosure illustrating a defect in the plastic enclosure components; -
FIG. 5B is a thermal signature of the single-cell battery module enclosure ofFIG. 5A from a top view perspective that illustrates a visual inconsistency at the defective region; and -
FIG. 6 is a flowchart illustrating steps performed by the thermal imaging system to detect defective welds. - The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.
- Referring now to
FIG. 1 , an exemplarythermal imaging system 10 for abattery module enclosure 12 includes alaser source 14, an infra-redthermal imaging camera 16, and aturntable 18.Plastic enclosure components 12 that are desired for welding are fixed to theturntable 18. For example, theturntable 18 may move theplastic enclosure components 12 between three different positions. At a first position, theplastic enclosure components 12 are fixed to theturntable 18. Theplastic enclosure components 12 are moved to a second position where thelaser source 14 generates welds at junctions between two or moreplastic enclosure components 12. Lastly, theplastic enclosure components 12 are moved to a third position where the infra-redthermal imaging camera 16 captures a thermal signature in order to verify the integrity of the welds. - A
control module 20 controls operation of thethermal imaging system 10. Thecontrol module 20 includes aturntable control module 22 that communicates with amotor 24 of theturntable 18 and adjusts a position of theturntable 18 during welding and thermal imaging of theplastic enclosure components 12. For example, theturntable control module 22 may be programmed to rotate the turntable 18 a predetermined number of degrees between each of the positions. Alaser control module 26 controls operation of thelaser source 14. For example, thelaser control module 26 turns thelaser source 14 on and off and may adjust operational parameters of thelaser source 14 such as a wavelength of alaser beam 28 that thelaser source 14 emits. Acamera control module 30 controls operation of the infra-redthermal imaging camera 16. For example, thecamera control module 30 turns the infra-redthermal imaging camera 16 on and off and may adjust operational parameters such as resolution and zoom. - In an exemplary embodiment, the
plastic enclosure components 12 comprise thermoplastics such as polymeric blends. Since thermoplastics are poor conductors, the weld temperatures of theplastic enclosure components 12 remain consistent for a period of time. Therefore, the infra-redthermal imaging camera 16 preferably acquires thermal signatures of the weldedplastic enclosure components 12 within a predetermined amount of time after the welding procedure is completed. For example, the infra-redthermal imaging camera 16 may be set to acquire the thermal signatures within five seconds after a welding procedure is performed. - An
image processing module 32 receives thermal signatures corresponding to theplastic enclosure components 12 from the infra-redthermal imaging camera 16. Adatabase 34 includes a template signature corresponding withplastic enclosure components 12 that have predetermined satisfactory welds. For example, a template signature may correspond withplastic enclosure components 12 that are rigorously inspected using microscopic technology to ensure satisfactory welds. The template signature includes one or more reference points that correspond with structure that is common to both the template signature and other potential thermal signatures. Therefore, theimage processing module 32 utilizes an image processing algorithm to locate a reference point on a thermal signature that corresponds with a reference point on the template signature. For example, the reference point may be a visible surface or edge of theplastic enclosure components 12. - An
image comparison module 36 receives the thermal signature from theimage processing module 32 and the template signature from thedatabase 34. Theimage comparison module 36 compares the thermal and template signatures to detect defectiveplastic enclosure components 12 or weak or non-existent welds. For example, theimage comparison module 36 may detect visual inconsistencies in the thermal signature along junctions where theplastic enclosure components 12 are welded. Based on the comparison, theimage comparison module 36 determines whether theplastic enclosure components 12 are satisfactory or unsatisfactory. For example, theimage comparison module 36 may compute a relative measure of deviation of the thermal signature from the template signature. A satisfactory thermal signature may correspond with a relative measure of deviation that is less than or equal to a predetermined value. For example, the predetermined value may be adjusted depending on a desired tolerance with which to inspect theplastic enclosure components 12. - Additionally, following the signature comparison the
image comparison module 36 stores the thermal signature in thedatabase 34 with the associated satisfactory or unsatisfactory identifier. Thecontrol module 20 includes adata analysis module 38 that reads stored thermal signature test results in thedatabase 34 and generates weld integrity statistics. For example, thedata analysis module 38 may track the relative rate of occurrence of defective welds for quality control purposes. - Referring now to
FIGS. 2A-2C , anexemplary battery module 46 includes aninner cavity 48 that houses a battery cell. Theinner cavity 48 is defined by multiple plastic enclosure components 50 that interface and are welded together along junctions between the plastic enclosure components 50. For example,FIG. 2C illustrates anenlarged view 52 of ajunction 54 between side and top plastic enclosure components 50-3 and 50-2, respectively, of thebattery module 46. A through transmission laser welding (TTLW) process is used to focus thelaser beam 28 at thejunction 54. For example, thelaser source 14 may include a plurality oflaser beams 28 that are utilized to continuously illuminate a desired area, although other laser source configurations are possible. Amelt pool 56 forms within aheat zone 58, which leaves a structural bond between the plastic enclosure components 50-2 and 50-3 when thelaser source 14 is turned off and themelt pool 56 cools. - Since thermoplastics typically have a low conductivity and the
laser source 14 has high focusing capabilities, theheat zone 58 is relatively small and presents little risk to components housed in theinner cavity 48. While thebattery module 46 illustrated inFIGS. 2A-2C is a single-cell battery module 46, those skilled in the art can appreciate thatbattery modules 46 may include multiple battery cells that are individually isolated and connected in series. - Referring now to
FIGS. 3A and 3B , in order for alaser beam 28 to reach thejunction 54 between plastic enclosure components 50, at least one of the plastic enclosure components 50-4 and/or 50-3 is transmissive to a wavelength of thelaser beam 28. In an exemplary embodiment, the wavelength of thelaser beam 28 is between 800 nm and 1100 nm, although other wavelengths are possible. Thelaser beam 28 penetrates plastic enclosure component 50-3 to create theheat zone 58 at thejunction 54 between the plastic enclosure components 50.FIG. 3A illustrates plastic enclosure components 50 that are free of defects prior to welding, and welds are made along a perimeter of the plastic enclosure components 50 to seal thebattery module 46 during the welding process.FIG. 3B shows a top view of the thermal signature 66 for the plastic enclosure components 50. Temperature differences at weld points 68 along the perimeter of thebattery module 46 are indicated by fluctuating colors on the thermal signature 66. - Referring now to
FIG. 4 , an exemplarythermal signature gradient 76 illustrates the appearance of varying temperatures on thermal signatures 66. For example, according to thethermal signature gradient 76, temperatures below room temperature do not stand out in the thermal signature 66 and temperatures required for thermoplastic welding appear very dark or opaque. Therefore, colors remain consistent with expected temperatures along weld points 68 as illustrated inFIG. 3B . Interior portions 78 (as shown inFIG. 3B ) of the weld points 68 appear very dark along the perimeter of the plastic enclosure components 50, and the colors lighten when moving away from theinterior portions 78. - Referring now to
FIGS. 5A and 5B , a plastic enclosure component 50-5 of abattery module 86 is defective. For example, achip 88 in the plastic enclosure component 50-5 may prevent a structurally sound weld from being generated at thejunction 54 between two plastic enclosure components 50-3 and 50-5.FIG. 5B shows a top view of athermal signature 90 for thebattery module 86 ofFIG. 5A . The consistency in color of thethermal signature 90 along the weld points 68 is broken at anarea 92 where thechip 88 is located. The typically dark color of theinterior portion 78 of the weld points 68 is missing and is replaced with a lighter color consistent withouter portions 94 of weld points 68. The image processing algorithm executed by theimage processing module 32 detects the inconsistency in thethermal signature 90 and identifies thebattery module 86 as defective before storing thethermal signature 90 in thedatabase 34. - Referring now to
FIG. 6 , a thermal imaging algorithm begins instep 102. Instep 104, control determines whether the next plastic enclosure components 50 desired for welding are in position. If false, control loops to step 104. If true, theturntable control module 22 adjusts a position of theturntable 18 so that the plastic enclosure components 50 are situated under thelaser source 14 for welding instep 106. Instep 108, thelaser control module 26 activates thelaser source 14 to generate the welds. Instep 110, theturntable control module 22 adjusts a position of theturntable 18 so that the plastic enclosure components 50 are situated within a field of view of the infra-redthermal imaging camera 16. Instep 112, thecamera control module 30 activates the infra-redthermal imaging camera 16 in order to acquire athermal signature 90 of the plastic enclosure components 50. - In
step 114, theimage processing module 32 receives thethermal signature 90 and locates a reference point that is consistent with the template signature 66. Instep 116, theimage comparison module 36 compares the thermal andtemplate signatures 90 and 66, respectively, and computes a relative measure of deviation of thethermal signature 90 from the template signature 66. Instep 118, control determines whether the relative deviation is greater than a predetermined value. If true, control proceeds to step 120. If false, theimage comparison module 36 identifies thebattery module 86 as satisfactory instep 122 and control proceeds to step 124. Instep 120, theimage comparison module 36 identifies thebattery module 86 as defective and control proceeds to step 124. Instep 124, theimage comparison module 36 stores thethermal signature 90 in thedatabase 34 and control ends. - The
thermal imaging system 10 of the present invention is utilized to verify proper welding of plastic enclosure components 50 ofbattery modules 86 such as battery cells for hybrid electric vehicles. Thethermal imaging system 10 is non-destructive and may be completely integrated with the laser welding process in order to identify defective welds immediately, which lowers costs and reduces manufacturing times. - Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and the following claims.
Claims (9)
1. A method for operating a thermal imaging system for a battery module enclosure that includes first and second battery module enclosure components between which a weld is formed, comprising:
acquiring a thermal signature of the weld within a predetermined amount of time after the weld is formed;
utilizing an image processing algorithm to locate a predetermined reference point in said thermal signature; and
comparing said thermal signature to a template signature in order to verify structural integrity of the weld.
2. The method of claim 1 further comprising using an infra-red thermal imaging camera to acquire said thermal signature.
3. The method of claim 1 further comprising utilizing an image processing algorithm that locates a structural feature that is common to both of said thermal and template signatures.
4. The method of claim 1 wherein the first and second battery module enclosure components comprise polymeric thermoplastics.
5. The method of claim 1 further comprising housing at least one battery cell for a hybrid electric vehicle in the battery module enclosure.
6. The method of claim 1 further comprising:
fixing the first and second module enclosure components on a turntable;
focusing a laser beam on the first and second module enclosure components in order to form the weld;
adjusting a position of said turntable so that the first and second module enclosure components are located within a path of said laser beam when the weld is formed; and
adjusting said position of said turntable so that the first and second module enclosure components are within a field of view sufficient to obtain said thermal signature.
7. The method of claim 1 further comprising:
computing a relative measure of deviation of said thermal signature from said template signature; and
identifying the weld as defective when said relative measure of deviation is greater than a predetermined value.
8. The method of claim 1 further comprising:
storing said template signature in a database;
verifying structural integrity of the weld; and
storing said thermal signature and a weld integrity value that is associated with said thermal signature in said database.
9. The method of claim 8 further comprising generating weld integrity statistics based on a plurality of weld integrity values that are stored in said database.
Priority Applications (1)
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US12/330,787 US7959353B2 (en) | 2005-08-24 | 2008-12-09 | Infra-red thermal imaging of laser welded battery module enclosure components |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US11/211,021 US8162020B2 (en) | 2005-08-24 | 2005-08-24 | Infra-red thermal imaging of laser welded battery module enclosure components |
US12/330,787 US7959353B2 (en) | 2005-08-24 | 2008-12-09 | Infra-red thermal imaging of laser welded battery module enclosure components |
Related Parent Applications (1)
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US11/211,021 Division US8162020B2 (en) | 2005-08-24 | 2005-08-24 | Infra-red thermal imaging of laser welded battery module enclosure components |
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US20090087083A1 true US20090087083A1 (en) | 2009-04-02 |
US7959353B2 US7959353B2 (en) | 2011-06-14 |
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US11/211,021 Expired - Fee Related US8162020B2 (en) | 2005-08-24 | 2005-08-24 | Infra-red thermal imaging of laser welded battery module enclosure components |
US12/330,787 Expired - Fee Related US7959353B2 (en) | 2005-08-24 | 2008-12-09 | Infra-red thermal imaging of laser welded battery module enclosure components |
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EP (1) | EP1929283B1 (en) |
JP (1) | JP4884472B2 (en) |
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CA (1) | CA2620084A1 (en) |
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JP2009506324A (en) | 2009-02-12 |
US20070047796A1 (en) | 2007-03-01 |
WO2007025021A2 (en) | 2007-03-01 |
EP1929283A2 (en) | 2008-06-11 |
EP1929283B1 (en) | 2014-10-08 |
WO2007025021A3 (en) | 2007-05-31 |
US7959353B2 (en) | 2011-06-14 |
US8162020B2 (en) | 2012-04-24 |
MX2008002579A (en) | 2008-03-14 |
CA2620084A1 (en) | 2007-03-01 |
JP4884472B2 (en) | 2012-02-29 |
CN101297194A (en) | 2008-10-29 |
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